Reclosable dispenser package, reclosable outlet forming structure and method and apparatus for making same

ABSTRACT

An aperture forming structure, which when attached to or integrally formed in dispenser packages for flowable substances allows reclosure and single or multiple uses. The aperture forming structure includes a break away tip member of thermoformable plastic. The break away tip includes a hollow protrusion from a surface. The intersection of the hollow protrusion and the surface is a fault line. Rupturing of the fault line creates an aperture from which the contents of the dispenser package may exit. A cap may be integrally formed with the aperture forming structure and detached for protecting the hollow protrusion or for closing the aperture created when the fault line is ruptured. The aperture forming structure can be made by heating a relatively stiff substantially flat thermoformable sheet of and then stretching the sheet to create a first and a second hollow protrusion in a tiered configuration. A rupture line is placed at the intersection of the first and the second protrusions. The sheet may be attached to a pouch or containment member formed from a flexible sheet which contains any flowable substance.

This non-provisional application claims priority to U.S. ProvisionalApplication Ser. No. 60/010,455, filed Jan. 23, 1996, and United StatesProvisional Application Ser. No. 60/035,737, filed Jan. 3, 1997 by thesame inventor of the instant non-provisional application, both of whichare herein incorporated by reference.

FIELD OF THE INVENTION

This invention relates to easy opening, self-contained, easy to use,single or multiple use dispenser packages capable of economical, highspeed production, manufactured from a broad range of materials, many ofwhich are recyclable. They may contain such products as syrups, cream,cheeses, salad dressings, shampoo, hand-cream, liquid detergents, motoroil, toothpaste pates, pet food and many other products. It additionallyrelates to a package which has the capability of dispensing thecontained product, e.g., mouthwash, cough syrup, confections, alcoholicbeverages, etc., directly into the mouth of the user, and which alsoincludes a reclosure cap member formed as an integral part of thepackage and which preferably is tethered to the package by a tether alsoformed integrally with the package. It will also be seen that the easyopening feature together with the reclosure cap and tether may be formedindependently and sealed or adhered to the surface of many packages suchas bags, milk containers, pouches, pillow packages (sachets), etc. tomake for very efficient low cost dispensing packages or squeeze bags.These squeeze bag type packages could dispense food pastes such as petfood, cremes, grease, yogurt, certain types of dough, cake frosting andcould be made of everything from treated, coated paperboard plasticfilms, foils, laminates or coextrusions of these materials. The easyopening means of this application in its preferred embodiment iscomprised of a drum-like protrusion from which a secondary frustoconical protrusion extends to create a tip which is encircled at itsbase by a fault line. To create the aperture this tip is broken away byapplying light lateral finger pressure. In order to protect thisbreakaway tip during shipment or for reclosing the aperture, a tetheredcap is also formed adjacent to the double protrusion. The tetherfunctions not only to hold the cap, thereby preventing the cap frombeing lost, but also to hold the cap [on the tip] in place by actinglike a spring.

In an alternate aperture forming system the initial drum like protrusionhas, instead of a frusto-conical breakaway tip, a fault line patterndefined in its top surface, so designed as to rupture to create anoutlet of various required shapes when a puncturing tool/plug is pressedinto said fault line pattern. Such puncturing tool/plug may be formedinstead of a cap and may be tethered or the cap may be double ended witha cap formation on one end and the puncturing tool/plug formation on theother. It will also be seen that a cap containing a protruding memberformed within the cap similar to the style of a flower would perform asa central punch when the cap is pressed over the drum shaped protrusion.It will further be seen that in certain instances where a metal foilliner is required for a flowable product such as an alcoholic drink thedrum shaped protrusion may be replaced by a moundlike protrusion with acentral fault line pattern. The reason for such a moundlike shapeinstead of the drum shape is to prevent the stretching of the foilbeyond its elastic limit at surface intersections in which case it wouldrupture during formation. Said pattern able to be punched open by aformed puncturing tool/plug said puncturing tool/plug may bethermoformed and tethered to the unit or may be independently made andthe tether may have a formed ring at its free end into which thepuncturing tool plug may be seated.

This invention also relates to a method and apparatus for manufacturingthe aforesaid formation and packaging, reliably at high speed, in manycases from fully recyclable material, so as to permit such packages tobe produced at low cost and, in many cases, recyclable. Additionally thepackages may use less plastic material than most other previously knownportion packages leading to source reduction and environmental benefitseven when non-recyclable materials are used.

BACKGROUND OF THE INVENTION

Various attempts have been made to provide a dispenser package in whicha product may be packaged in the quantity normally required for singleor multiple uses, and from which the contained product may be dispensed.

One type of such dispenser packages is a pillow pouch or sachet,typically made of relatively thin plastics and foils or combinations oflaminated plastics and foils. These packages are most frequentlyencountered as containers for catsup, mustard, other condiments,homecare preparations such as hair conditioners, dyes and cremes, etc.Although this type of package is universally used, it is alsouniversally disliked by the consumer. In order to access the contents,the pouch must be held in one hand while a tearing motion and force areapplied by the other hand. Creating the initial tear to break thepackages seal is often very difficult, often requiring the assistance ofthe user's teeth. Moreover, once the initial tear is created, thelaminated foil and/or plastic material not only often tears in anuncontrolled fashion, but the holding pressure exerted by one of theuser's hands often forces the contents out of the envelope not onlybefore the user is ready to apply the contents, but even before thetearing motion is complete. Opening these packages leads to frayedtempers, broken fingernails, and chipped teeth, as well as otherproblems. The user must also use both hands to open the container. Inthe case of invalids, arthritis sufferers and other handicapped people,opening these packages is virtually impossible. Yet another problemassociated with these prior packages is the impossibility of efficientreclosure, thereby precluding multiple use of the package, withconsequent waste of the unused contents. Further disadvantages includethe sachet's inability to function effectively with low viscosityproducts such as coffee cream, mouthwash or alcoholic beverages, due tothe inability of the torn opening to control the direction of flow ofsuch liquids from the package. These packages also are generally totallyunrecyclable, and therefore become environmental pollutants. Asabove-mentioned however, should continued use of these sachets bepreferred, then the easy opening feature of this application may bereadily and economically adhered to the sachet to make for an easyopening, reclosable, high-barrier package.

Another dispenser package is the peel-top cup used for butter,margarine, syrup, sauces, salad dressing, and other similar products.This type of package requires good eyesight and manual dexterity. Suchpackages are often used as coffee creamers and have many disadvantages,including difficulty in peeling off the top in order to open, as well asdifficulty in pouring, accidental spilling, and the inability to bereclosed so as to preclude more than a single use. Again the inventionsdescribed herein can be adhered or integrally formed into these packagesto make them easy opening and reclosable. Yet another type of dispenserpackage is the unsealed corrugated paper package used for salt and/orpepper, which upon bending along an interrupted line cut through thecorrugations forms an opening through which the salt or other materialcontained in the package may flow. These packages only dispense dry,solid flowables with the assistance of gravity, and cannot be used tocontain, no less dispense, "wet" or liquid flowable materials. Thepackage of this invention can contain and readily dispense both liquidsand dry granular products.

Small, very expensive, metal capped bottles are used for alcoholicdrinks and are either poured or consumed directly from the bottle. Thesebottles may be reclosed, but often are sized for a single drink so theydo not have to be reclosed. The instant package can be used foralcoholic beverages at a fraction of the cost of the bottles.

Everyone is familiar with the ubiquitous gable top milk carton andeveryone is familiar with the varying degrees of difficulty in openingthem. These range from fingernail breaking to just plain unopenablewithout a knife or other tool.

They never truly reclose and at best are messy and unclean looking. Inthe U.S. there has been a move toward mounting a screw-on capcombination comprising a threaded nozzle member which is sealed onto oneof the slanted gables of the carton and the other is an unattachedscrew-on cap. This little injection molded duo is costly to make and toinstall, possibly on the order of 3 to 5 cents and is commonly used onlarge gable top juice containers in the half gallon size. These areexpensive, high profit items selling for about three dollars each andcan bear the extra tariff for the screw-on outlets. There are howeverbillions of these gable top units sold annually for milk and cream invarying sizes from half-pints to half gallons. Producers however arereluctant to increase carton cost significantly and the public continuesto use difficult to open cartons.

The instant invention makes available a sealed and tamper evident outletwith a tethered cap, both formed in a single, small plastic unit whichcan be readily sealed or adhesively attached to the gable over a smallpre-made hole. It is ultra low cost and may be made of polypropylene,high density polyethylene, PVC. Polyester etc. utilizing materialcosting small fractions of a cent. It will be seen that the cap serves adouble purpose. It enables the outlet to be reclosed after opening andof equal importance, since the cap is in place over the breakaway tipduring shipment it protects the tip from being accidentally hit orsubjected to any forces which may open the outlet.

It may be seen that the lower drum-like formation beneath the breakawaytip may be elongated so that when the tip is broken away, an elongatednozzle remains which would allow the flowable substance to be ingesteddirectly from the container or as in the case of motor oil, being poureddirectly into the engine oil inlet. Another disadvantage currentlyexperienced with dispensing packages is the closing of the outletopening. Closing the outlet opening of tubes is presently accomplishedby means of an injection molded screw-on cap which normally includes acompressible gasketing material. The end of the tube requires a matingthread to match the cap. Both the separately molded gasketed cap and thethreaded tube result in increased manufacturing costs. Additionally, thecap, as often as not, is dropped and/or lost while it is being threadedon or off. Furthermore, there has been a growing trend to manufacturesuch tubes at still greater cost by providing hinged caps with a flatend surface which permits the tube to stand upright. Thus, the capmembers currently in use have the disadvantage that they tend toincrease the overall cost of manufacture of the dispensing package.

OBJECTS OF THE INVENTION

It is therefore an object of this invention to provide a new andimproved means of creating an aperture in a thermoformable plasticmaterial as well as an integrally formed cap and tether where necessary.

A further object is to form independently such aperture creating meanswith or without a cap and/or tether for adhesion to other forms ofpreviously difficult to open or non-reclosable packaging.

Another object of this invention is to provide new and improveddispenser packages.

Another object of this invention is to provide a new and improvedaperture-forming structure for a dispenser package which allows the userto easily and controllably dispense the contents of the package directlyto the user's mouth or in a directionally controlled manner, as desired.

Another object of this invention is to provide a new and improvedaperture-forming structure for a dispenser package which opens easilyand reliably and yet which can be manufactured economically and at highspeed.

Another object of this invention is to provide a new and improvedreclosable dispenser package so that the contents thereof may bedispensed in consecutive uses and the outlet opening reclosed betweenuses.

A further object of this invention is to provide a new and improvedreclosable package with an attached cap member formed from the sameplastic film which cap member may be thereafter placed over the unopenedaperture forming means to protect it and/or to reclose the package afteropening.

Another object of this invention is to provide a new and improvedreclosable package and removable cap member which may be formed as anintegral unit and where the cap member is attached to an integrally madetether and remains attached to the package and which may be placed overthe unopened aperture forming means to protect it from changes oraccidental opening during shipping and handling.

Another object of this invention is to provide a new and improvedreclosable package and tethered cap member which may be formed as anintegral unit from a thermoformable material.

Another object of this invention is to provide a new and improvedreclosable package and tethered cap member which may be formed as anintegral unit from a thermoformable plastic material that is recyclable.

Another object of this invention is to provide a new and improveddispenser package and cap member wherein the cap member has anopen-ended top of predetermined shape so that, upon placing the cap overthe aperture of the package the contents may be dispensed in such shapedstream.

Another object of this invention is to provide a new and improveddispenser package and cap member wherein the cap member includes autensil device such as tiny protrusions or a flattened surface structureso that the cap member may function as a tool to brush, spread, orotherwise handle the contents dispensed from the package.

Another object of the invention is to replace the cap member with a dualfunction punch/plug member capable of punching through a toughpre-scored formation to create an aperture and to further act as a plugto close said aperture.

A still further object of this invention is to provide a new andimproved method of making a dispenser package embodying the aforesaidfeatures.

Another object of this invention is to provide a new and improved methodof thermoforming a dispenser package from a recyclable plastic materialat high speed and yet provide a finished package which may be easily andreliably opened by the user.

Another object of this invention is to provide a new and improvedapparatus for forming an aperture-forming structure for a dispenserpackage.

Another object of this invention is to provide a new and improvedapparatus for forming a nozzle-like aperture structure in a dispenserpackage so that, upon opening, the contents of the package may bedispensed in a directionally controllable manner.

Another object of this invention is to provide a new and improvedself-centering and self-aligning punch and die apparatus adapted toaccurately and reliably form a thermoformable material into a hollowtip-like configuration having a peripherally extending fault line so asto permit the tip to be readily broken away by the user to form anaperture opening through which the contents of the package may bedispensed.

The foregoing specific objects and advantages of the invention areillustrative of those which can be achieved by the present invention andare not intended to be exhaustive or limiting of the possible advantageswhich may be realized. Thus, these and other objects and advantages ofthe invention will be apparent from the description herein or can belearned from practicing the invention, both as embodied herein or asmodified in view of any variations which may be apparent to these ofordinary skill in the art, the same being realized and attained by meansof the parts, constructions and instrumentations, and combinationsthereof, as well as in the steps and processes pointed out in theappended claims. The present invention resides in the novel parts,constructions, arrangements, combinations, steps and processes, andimprovements, herein shown and described.

SUMMARY OF THE INVENTION

Briefly described this invention is directed to a new reclosableaperture forming means which may be formed with an integrally formed capmember which may be tethered to said aperture forming means to create aunit which may be independently formed and adhesively or sealinglyattached to a container wall or surface over a hole in said containerwall to create an easy opening, reclosable, when necessary, dispensingpackage. Said reclosable aperture forming means embodying an integral,hollow protrusion member preferably comprised of two stages, a drumshaped base from which extends a generally conical or frusto-conicaltip, said tip member having a fault line encircling it at its juncturewith the flat top surface of the first drumlike formation which may bereadily broken off to form an opening through which the contents of thepackage may be dispensed in a directionally controllable stream. Afterthe tip of the protrusion member is broken off by applying light lateralfinger pressure, the desired quantity of the contents may thereafter beexpelled through the opened nozzle-like outlet by gentle hand squeezingof the package.

In a second embodiment the entire reclosable aperture forming means maybe integrally formed into what will become an easy to use reclosabledispensing package. In this second embodiment a generally relativelyflexible, compressible pouch or container member is sealably attached toa cover member forming the top or lid of the package. The cover memberincludes the new reclosable aperture forming means and tethered capmember as described above and similarly used.

In another desirable embodiment the pouch or container member has theintegral hollow protrusion and tethered cap member thermoformed into theunderside of its relatively stiff rim. The advantage of this versionbeing that the cover member then becomes a relatively thin skinlikemember which is very easy to print and less expensive than the formedupper cover member.

The aforesaid cap member which is initially formed with the package asan integral unit is preferably formed along one peripheral edge ofeither the cover member forming the top or lid of the package relativelyclosely adjacent to the breakaway protrusion member or on the undersideof the rim. A cut line may create a tether member which permits the capmember to be mechanically removed by the user from its molded positionin production and placed over the opened nozzle-like aperture formingmeans so as to protect the breakaway tip during shipping and handling,while remaining tethered to the package. As also preferably embodied,the aforesaid cap member permits the end user of the package to readilyopen or reclose the package after each use.

In other alternative embodiments of the dispenser package of the presentinvention:

(i) the breakaway protrusion member forming the aperture in the packagemay be broken off at the surface of the cover member forming the top orlid of the package, thereby eliminating the nozzle-like outletconfiguration in those applications where the contents of the packagedon't require nozzle formation;

(ii) the cap member may be formed with miniature protrusions to act likea brush, or may have some other desired shape to perform some otherdesired tool function for use in handling the contents dispensed fromthe package, such as by brushing or spreading;

(iii) if reclosing the package is not required, the cap member may beopen-ended having a predetermined shape such that, upon placing the capmember over the nozzle-like aperture of the package, the contents may bedispensed in such shaped stream;

(iv) the cap member may be provided with an internal central plugdimensioned to mate with the opening formed in the dispenser package tothereby serve as a plug to further ensure sealing of the opening afterremoval of the breakaway protrusion member; and

(v) the breakaway protrusion and tethered cap members may be formed in aportion of the cover member which extends beyond one end of thecompressible pouch member at a predetermined angle and communicates withthe product contained in the pouch by means of a shallow neck orchannel, thereby facilitating application of the contents of the packageonto a surface, such as, e.g., toothpaste onto a toothbrush or glue ontoa break line. Alternatively, the breakaway protrusion member may beformed in the cover member directly over the pouch portion with the capformed at an adjacent small flat area. This method yields a somewhatlarger pouch volume while using the same total amount of material.

It will be understood that the foregoing preferred embodiments of thedispenser package of the present invention may be thermoformed from awide variety of plastic materials, including, e.g., PP (polypropylene)Barex, HDPE (high density polyethylene), HIPS (high impact polystyrene)and foamed HIPS, as well as various laminations and/or coextrusions ofthe aforesaid materials and other plastic materials, including, e.g.,PP/EVOH (ethylene vinyl alcohol)/PP; Barex/PP; Barex/EVOH/PP; PET(polyethylene tetrafluoride)/LLDPE (linear low density polyethylene);PET/EVOH/LLDPE; PVC (polyvinylchloride)/LLDPE; NY (nylon)/LLDPE; andNY/EVOH/LLDPE. Alternatively, the aperture forming means and thedispenser packages of the present invention may be formed by injectionmolding.

It also will be understood that the foregoing preferred embodiments ofthe dispenser packages of the present invention may be manufactured in awide variety of sizes, as desired, although the preferred size range isfrom about 2 ml capacity to about 4 fluid ounce capacity. Similarly, theaforesaid package may be manufactured in a wide range of dimensions. Atypical size for a package containing 30 ml or 1 fluid ounce of materialis on the order of about 1 inch deep by about 1 inch wide by about 3 to4 inches long, which fits comfortably in the palm of the hand of mostusers. Furthermore, the independent formations of aperture forming meansand the tethered caps may be applied to a very wide range of packagedfrom single use sizes to half gallons.

Briefly described, as preferably embodied, the apparatus of the presentinvention forming the preferred aperture-forming protrusion member inthe cover member of the dispenser package includes a two-stage punchmember which advances to engage and clamp a thermoformable materialagainst a self-centering and self-aligning hollow anvil member. Thefirst punch member advances to initially form a hollow, drum-shapedprotrusion in a specific heated area of the thermoformable material.Thereafter, a second punch member preferably located within, andmoveable relative to, the first punch member continues to advanceforward. The second punch member includes a first generallyfrusto-conically shaped surface adapted to form a substantiallycylindrical or frusto-conically shaped hollow tip member extending fromthe drum-like protrusion formed by the first punch member. At the momentformation of the hollow tip member is completed, the forward advancementof the second punch brings a second shallow conical surface intocooperating engagement with the peripheral edge or rim defining thehollow portion of the anvil member to thereby compress the wall of theformed hollow tip about a peripheral portion thereof to create aweakened fault line in the hollow tip protrusion member. As herepreferably embodied, the aforesaid punch and anvil members create afault line at the base of the aforesaid hollow tip protrusion memberwhich extends continuously about the periphery thereof.

In an alternative embodiment of the apparatus of the present invention,the heated sheet of thermoformable material is clamped against the anvilmember and a single stage punch member having a generallyfrusto-conically shaped forward end portion is thereafter advanced toform the aforesaid hollow, substantially cylindrical or frusto-conicallyshaped tip member. At the moment formation of the hollow tip member iscompleted, the rim of the anvil member compresses the wall of the hollowtip member about the periphery thereof to create a weakened fault line.It will be seen that the heated thermoformable film (material) may beclamped against a relatively thin plate spaced away from the anvil whichcontains an accurately aligned hole centered on the aperture of theanvil member. In this embodiment, between the punch and anvil the filmwill be formed into a conical member as the punch is advanced throughthe plate and said conical member will then be further formed until itcontacts the peripheral edge or rim at the opening of the aperture inthe anvil. This alternate apparatus creates a fault line banding orgirdling the formed conically-shaped tip member at a predetermined pointbetween its base and its apex.

It will be appreciated by those skilled in the art that the foregoingvarious brief descriptions and the following detailed description areexemplary and explanatory of the present invention, but are not intendedto be restrictive thereof or limiting of the advantages which can beachieved by the invention or various combinations thereof. Theaccompanying drawings, referred to herein and constituting in parthereof, illustrate preferred embodiments of the invention and, togetherwith the detailed description, serve to explain the principles of theinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side elevation view of a dispenser package constructed inaccordance with the present invention with an integrally formed capmember;

FIG. 2 is a top plan view of the dispenser package of FIG. 1;

FIG. 2a is a perspective view of a dispenser package constructed inaccordance with the present invention with an integrally formed capmember on the underside of the containment members rim and their skinlike unformed cover member;

FIG. 3 is an end view of the dispenser package of FIG. 1;

FIG. 3a is an end view of the dispenser package of FIG. 2a showing anunformed very thin flexible cover member;

FIG. 4 is a side view in elevation, partly sectional, of an apparatusconstructed in accordance with the present invention for forming thebreakaway tip and nozzle protrusion members in a heated sheet ofthermoplastic material;

FIG. 5 is an enlarged sectional view, partly in elevation, of the firstand second punch members and the self-aligning hollow anvil memberillustrated in FIG. 4, this view illustrating formation of the firstprotrusion member in the thermoplastic sheet material;

FIG. 6 is an enlarged view similar to FIG. 5, illustrating formation ofthe second protrusion member in the thermoplastic sheet material;

FIG. 7 is an enlarged view of FIG. 6, illustrating formation of theperipherally extending weakened fault line at the base of the secondprotrusion member;

FIG. 7a an enlarged side plan view of first and second protrusionmembers according to one embodiment of the present invention;

FIG. 7b is an enlarged side plan view of first and second protrusionmembers according to one embodiment of the present invention;

FIG. 8 is an isometric view of the dispensing package of FIG. 1;

FIG. 9 is an enlarged isometric view of the dispensing package of FIG.8, illustrating the cap member removed from its molded position andplaced over the breakaway tip protrusion member;

FIG. 10 is a schematic illustration showing the use of a hollow punchmember for forming a central sealing plug member in the cap memberillustrated in the preceding drawings;

FIG. 11 is an isometric view of a cap member formed with a central plugfrom the apparatus of FIG. 10;

FIG. 12 is an enlarged cross-sectional view, partly in elevation,illustrating an alternative embodiment of the punch and anvil apparatusof the present invention, wherein a single punch member forms a hollowfrusto-conical protrusion in the surface of the cover member for adispenser package and the anvil member compresses the wall of the tip toform a peripherally extending fault line on the surface of theprotruding tip;

FIG. 12a is an enlarged cross-sectional view, partly in elevation,illustrating an alternative embodiment of the punch and anvil apparatusof the present invention, wherein a single punch member forms a hollowfrusto-conical protrusion having a right-cylindrical base in the surfaceof the cover member for a dispenser package and the anvil membercompresses the wall of the tip to form a peripherally extending faultline on the surface of the protruding tip;

FIG. 12b is an enlarged cross-sectional view, partly in elevation,illustrating an alternative embodiment of the punch and anvil apparatusof the present invention, wherein a single punch member having aspherical tip forms a hollow mound protrusion in the surface of thecover member for a dispenser package and the anvil member compresses thewall of the tip to form a peripherally extending fault line on thesurface of the mound;

FIG. 13 is a schematic elevation view of the breakaway tip formed by thepunch and anvil members illustrated in FIG. 12;

FIG. 13a is a schematic elevation view of the breakaway tip formed bythe punch and anvil members illustrated in FIG. 12a;

FIG. 14 is a top plan view of another embodiment of a dispenser packageconstructed in accordance with the present invention, wherein thebreakaway tip and cap member are formed in a lateral extension of thecover member and the breakaway tip member communicates with thecontainment pouch through a shallow channel member;

FIG. 15 is a side view of the embodiment illustrated in FIG. 14;

FIG. 16 is an end view of the embodiment illustrated in FIG. 14;

FIG. 17 is a side view of the embodiment of the invention illustrated inFIG. 14, wherein the lateral extension of the cover member also extendsangularly downwardly;

FIG. 18 is a schematic view of an alternate embodiment of the capmember, formed with bristles or nubs on its outer surface;

FIG. 19 is a schematic view of another alternate embodiment of the capmember, formed with a flattened spreader tool utensil on its outersurface;

FIGS. 20a-d are partial end views of still other alternate embodimentsof the cap member of the present invention, each view illustrating anopen-ended cap member;

FIG. 21a is a top plan view of a reclosable outlet aperture formingstructure which can be applied to various forms of containers inaccordance with an alternate embodiment of the present invention;

FIG. 21b is a side view of the reclosable outlet aperture formingstructure shown in FIG. 21a;

FIG. 22a is a perspective view of the reclosable outlet aperture formingstructure of FIGS. 21a-b, as applied to a milk carton, in which the capis placed over the outlet;

FIG. 22b is a perspective view of the reclosable outlet aperture formingstructure of FIGS. 21a-b, as applied to a milk carton, in which the capis removed from the outlet so as to allow removal of the breakawayoutlet tip;

FIG. 22c is a perspective view of the reclosable outlet aperture formingstructure of FIGS. 21a-b, as applied to a milk carton, in which thebreakaway tip is removed from the outlet to form an openingtherethrough;

FIG. 22d is a perspective view of the milk carton of FIGS. 22a-c, inwhich the breakaway tip is removed from the outlet to form an openingthrough which milk is being poured;

FIG. 23 is a side view of a low profile breakaway tip in accordance withanother embodiment of the present invention;

FIG. 23a is a side view of a low profile breakaway tip in accordancewith another embodiment of the present invention;

FIG. 24 is a top view of the low profile breakaway tip of FIG. 23;

FIG. 24a is a top view of the low profile breakaway tip of FIG. 23a;

FIG. 25 is a perspective view of the low profile breakaway tip of FIG.23 with the removed breakaway tip shown in phantom;

FIG. 26 is a side view of a cap for use with the low profile breakawaytip of FIG. 23;

FIG. 27 is a side view of a another embodiment of the present inventionwhich utilizes a twist-lock or twist-threading arrangement to secure thecap to the base formation;

FIG. 28a is a perspective view of another embodiment of the presentinvention in which a tethered plug is used to open and close apre-scored surface;

FIG. 28b is a perspective view of the embodiment of FIG. 29a in whichthe pre-scored surface has been opened;

FIG. 28c is a perspective view of the embodiment of FIG. 28a in whichthe plug has been placed in the outlet hole, thereby opening the holealong the pre-scored surface and/or plugging the hole;

FIGS. 29a-d are top views of the outlet of the embodiment of FIG. 28adepicting various types of scored surfaces formed in the outlet; and

FIGS. 30a-d are side views of the scored surfaces shown in FIGS. 29a-d,in which each of the scored surfaces haves been penetrated to create anopening therethrough and a flap descending from the surface;

FIG. 31 is a partially elevated side view of an outlet forming structureaccording to an alternative embodiment of the present invention, havinga punch/plug and a scored mount, as applied to a milk carton;

FIG. 32 is a top plan view of the outlet forming structure of FIG. 31;

FIG. 33 is a side plan view of the outlet forming structure of FIGS. 31and 32;

FIG. 34 is an enlarged elevated view of the outlet forming structure ofFIGS. 31-33;

FIG. 35 is an enlarged side plan view of the outlet forming structure ofFIGS. 31-34 showing the mound as punctured by the punch/plug;

FIG. 36 is an enlarged side plan view of the mound of FIGS. 31-35;

FIG. 37 is a side plan view of an alternative embodiment of the presentinvention in which an outlet forming structure, having a breakaway tipand cap, is applied to a foil package;

FIG. 38 is an enlarged side elevational view of the outlet formingstructure of FIG. 37;

FIG. 39 is an elevated plan view of an alternative embodiment of thepresent invention as applied to a foil package;

FIG. 37a is a side plan view of an alternative embodiment of the presentinvention in which an outlet forming structure is applied to a foilpackage;

FIG. 38a is a front plan view of the outlet forming structure of FIG.37a;

FIG. 39a is an elevated plan view of the outlet forming structure ofFIGS. 37a and 38a;

FIG. 40 is a partial elevational view of an outlet forming structureaccording to another alternative embodiment of the present invention,having a snap-in auxiliary punch/plug/cap and protrusion member, that ismanufactured by a pick-and-place method;

FIG. 40a is an enlarged side plan view of the outlet forming structureof FIG. 40 showing the punch/plug/cap puncturing the protrusion member;

FIG. 41 is a top plan view of an alternative embodiment, wherein theoutlet forming structures are formed from a single thermoplastic web ina mating arrangement;

FIG. 42 is a side plan view of an alternative embodiment of the presentinvention in which the reclosable container is provided with a scoredprotrusion and a dual purpose tethered punch/cap;

FIG. 43 is a top plan view of the reclosable container of FIG. 42;

FIG. 44 is a top plan view of the reclosable container of FIGS. 42 and43, wherein the tethered punch/cap is securely fastened over the scoredprotrusion;

FIG. 45 is an elevated plan view of an outlet forming structureaccording to one embodiment of the present invention;

FIGS. 46a-c are side plan views of a container for use with an outletforming structure according to the present invention;

FIG. 47 is an elevated plan view of the container of FIGS. 46a-c withthe outlet forming structure of FIG. 45 mounted thereon;

FIG. 48 is a top plan view of a container according to an embodiment ofthe present invention;

FIG. 49 is a side plan view of the container of FIG. 49;

FIG. 50 is a side plan view of the container of FIGS. 48 and 49 in aclosed position;

FIG. 51 is a side perspective view of the container of FIGS. 48-50;

FIG. 52 is a side elevational view of a container according to anembodiment of the present invention;

FIG. 53 is an enlarged side plan view of the outlet forming structure ofFIG. 52; and

FIG. 54 is a top plan view of a section of a web of thermoformablematerial having a series of outlet forming structures formed therein.

DETAILED DESCRIPTION OF VARIOUS PREFERRED EMBODIMENTS

Referring now more particularly to FIGS. 1-4 and 9 of the accompanyingdrawings, there is illustrated a dispensing package indicated generallyat 10 according to the present invention. The package 10 can be used forsingle or multiple uses and can be reclosed for further use.

As illustrated in FIGS. 1 and 4, the package 10 includes a cover member11 formed from a flexible but relatively stiff generally flat sheet 12of a thermoformable plastic material most suitable to the productcontained and the protection that the contained product requires.

Materials such as high-impact polystyrene (HIPS), high densitypolyethylene (HDPE) polyester, HDPE/EVOH (high densitypolyethylene/ethylene vinyl alcohol), Barex, polypropylene, etc. may beused. HIPS, HDPE, and HPDE/EVOH are each low cost and can be recycled.HDPE/EVOH creates a superior O₂ barrier.

As will be understood by those skilled in the art, whereas plastics ofsimilar material may be heat-sealed or bonded together, heat sealingdifferent plastics together requires an adhesive layer. Preferably,linear low density polyethylene (LLDPE) is used as such a layer. Thus,multi-layered plastics formed by coextrusion may be sealed together toform sheet 12 having sealant/barrier 14 of the present invention.

Also suitably bonded to one face of bonded sheet 12, 14 is a flexiblesheet 18 forming at least one pouch chamber 22 adjacent one face of therelatively stiff sheet 12 or bonded sheet 12, 14 for containing apreferably flowable substance, e.g. a dry powdered or granulatedmaterial or a liquid material of any suitable viscosity capable offlowing under light to moderate hand pressure.

Advantageously, and as here preferably embodied, the layer of a suitablesealant/vapor impervious barrier material 14 is suitably integrallybonded to sheet 12 on the inner surface 16 which faces flexible sheet18. Flexible sheet 18, advantageously formed by conventional means, suchas vacuum forming, pressure forming, mechanical forming or combinationsthereof, is likewise suitably integrally bonded to either inner surface16 or sealant/barrier 14 of sheet 12, as the case may be.

The bonds between substantially flat relatively stiff sheet 12,sealant/barrier material 14 and flexible sheet 18 also may be formed byconventional means known to persons of ordinary skill in the packagingart, such as welding, heat sealing, or adhesive or cohesive bonding. Itwill be understood that the particular bonding method selected dependsupon the particular properties of the materials used and the flowablesubstance(s) to be contained in the package.

Advantageously, and as preferably embodied, sheet 12 is preferably madeof polypropylene (PP), Barex, high impact polystyrene (HIPS) orhigh-density polyethylene (HDPE), but when combined with barrier 14 maybe made of polystyrene, polyester, EVOH (ethylene vinyl alcohol),polyvinyl chloride (PVC), polyethylene tetrafluoride (PET) or nylon, ora copolymer thereof, and barrier 14 is made of a suitable sealant/vaporimpervious barrier material, preferably comprising saran and foillaminate, or comprising a laminate of foil and vinyl, or foil alone,depending on the nature of the contents to be contained.

A particularly tough high barrier construction comprises saran laminatedon each side with polyethylene (sold by Dow Chemical Co. under the name"Saranex") as barrier sheet 14, in turn laminated onto polystyrene orpolyester, forming the flexible but relatively stiff sheet 12. Thethickness of sheet 12 varies according to factors, such as theproperties of the materials used, the flowable substance contained, andthe intended usage. A generally utilized range is 4-12 mils(0.004-0.012"). As previously noted, sheet 12 preferably is somewhatflexible, although more rigid than the material 18 forming pouch 22, andpreferably is stiffened by raised portion 11a formed in cover 11 in thepreferred construction of package 10.

It will be understood by those of ordinary skill in the art that thebonds formed between materials 12, 14 and 18 can be obtained by theconventional means previously described, again depending on the natureof the flowable substance being contained.

It will be seen from the foregoing that the structure of FIGS. 1 and 2forms an enclosed pouch or chamber 22 between the flexible sheet 18 andthe relatively stiff member 12, 14 in which a preferably flowablesubstance is contained and from which the contained substance isdispensed.

In accordance with the present invention as preferably embodied, therelatively stiff generally flat sheet 12 forming cover 11 includes anaperture-forming protrusion structure 30 which includes a neck member 32and a breakaway tip member 34 so that, upon removal of tip 34, neck 32forms a nozzle-like aperture in package 10 through which the contentsmay be dispensed in a directionally controllable manner.

Neck and tip protrusions 32, 34 preferably are substantially hollow,substantially cylindrical and tip 34 preferably is substantiallycylindrical or frusto-conical. In the preferred embodiment as shown inthe plan view of FIG. 3, the aperture-forming protrusion structure 30 islocated in cover 11 directly over pouch 22 so that, when opened, nozzleaperture 32 communicates directly with the contents of pouch 22.

In accordance with the present invention, as preferably embodied,dispenser package 10 includes a cap member 110 formed as an integralpart of cover 11. Advantageously, cap member 110 is removable from cover11 along a line.

It will be seen that the cap 110 protects the breakaway tip structure 30from inadvertently breaking off during shipping and handling prior touse, as well as providing a means to reclose the package after opening,i.e., after the protrusion tip member 34 is broken off. Thus, cap 110protects the remaining contents of the package after each use,permitting multiple uses. The advantage of the tethered embodiment ofthe invention is that it costs practically nothing, acts as a sidepressure spring to maintain the cap on the neck 32 at the opening, actsas a grasping member to assist removal of the cap for each subsequentuse, and prevents loss of the cap before the contents of the packagehave been fully dispensed and the package is ready to be disposed of.Further details of the cap are explained below.

In practically all cases, however, it is believed preferable to providethe two-stage breakaway tip configuration since the first projectingcylindrical formation 32 acts as a nozzle yielding directionallycontrollable product dispensation, after the tip, i.e., secondprotrusion 34, is broken off. Low and medium viscosity flowable productstend to squirt "side-ways" or spurt in non-controllable directions, whenpassing through an aperture formed in the plane of the cover member.Furthermore, elevating the breakaway tip from the surface of the covermember greatly enhances its ease of use with no practical increase inmanufacturing cost.

In use, as here preferably embodied, package 10 preferably is positionedso that pouch or chamber 22 rests in the palm of the hand with the thumbresting on the cover 11. The thumb or finger of the holding hand, or theuser's other hand, if desired, may then be used to apply a light fingerpressure against the side of protrusion tip 34, i.e., the breakaway tip,thereby causing tip 34 to break off, leaving an open neck or nozzle-likeaperture 32.

Once tip 34 is removed and the package thereby opened, the contents ofthe package 10 may be expelled. This method of use depends on the typeof substance contained in the package and where the user would like toplace the contents. For example, if the package contains toothpaste, theopen nozzle 32 preferably would be placed over a tooth brush, whereupongentle squeezing of the package 10 will force the toothpaste onto thetoothbrush. If the contents of the package are intended to be placeddirectly into the user's mouth, or the mouth of a patient, such as fororal medicine or mouthwash, the open nozzle 32 then may be placeddirectly into the mouth and a portion, or all, of the contents may thenbe directed into the mouth by squeezing the package. When the desiredquantity of the contents of the package has been expelled, if somecontents remain, package 10 may then be reclosed for future use byplacing cap 110 over the open nozzle 32.

As previously mentioned, as here preferably embodied, package 10 furtherincludes a cap 110. While cap 110 may be formed separately from theother elements of package 10, in the preferred embodiment cap 110 isintegrally formed with and is at least partially detachable from therelatively stiff sheet 12 forming cover 11, as shown in FIGS. 1-3, 9-10,15-18, 22-23d, 29a-c, 32-35, 38-40, and 42-47, for example.

As shown in FIGS. 1-3 and 8-9, cap 110 preferably is located at onecorner in cover 11 so as to overhang pouch 22. A cut line 114 allows cap110 to be easily removed from cover 11. Advantageously, as best seen inFIG. 10, cut line 114 extends only partially along the edge of cover 11so as to provide a tether 130 to maintain cap 110 attached to package 10even after the cap is paced over either the aperture-forming structure30 or over the open nozzle 32.

Cap 110 typically is unthreaded and is dimensioned to fit smoothly, yetsecurely, over the necked protrusion 32, which preferably also is smoothand unthreaded, both before and after removal of tip 34. Cap 110 has abase 126 which lies flat against the top of cover 11. Tether 130 hasseveral advantages. First, it has been discovered that the tether 130acts as a spring pressing the cap against the sidewall of the neckedprotrusion 32, thereby assisting to hold cap 110 in place when it isplaced over the necked protrusion 32. Additionally, tether 130 providesthe added benefit of preventing the cap 110 from becoming lost andallows the user to grip the tether 130 to assist in removal of the cap130 from the aperture-forming structure 30 or from open nozzle 32.

Cap 110 of the present invention can be designed in several differentembodiments. For example, in the embodiment shown in FIGS. 10 and 11,the cap can be formed from a hollow punch member 120 that forces thematerial into a hollow female member 122 with a central protrusion 124to form a cap with a central plug 126.

An alternative to the embodiment shown in FIGS. 1-4 is shown in FIGS. 2aand 3a. As shown, the container 10a has generally the same configurationas container 10 depicted in FIGS. 1-3 is made of the same materials.Specifically, pouch 22a is formed between a flexible sheet 18a and thevery thin skin like sheet 12a, 14a, in which a flowable substance iscontained. Unlike the previous embodiment, the aperture-formingprotrusion structure 30a is formed on the underside of the flat sheet18. Similarly, the cap 110a is formed on the underside of the sheet 18.With such an arrangement, not only are the neck and tip protrusions 32a,34a of the protrusion structure 30a protected from accidental rupture,but also the container 10a is provided with a low cost flexible cover.In order for the protrusion structure 30a to be in fluid communicationwith the contents of the pouch 22a, the pouch 22a is provided with achannel 11b which communicates with the protrusion structure.

It will be understood that the aperture-forming protrusion structure 30may be made by a variety of methods and apparatus. In accordance withthe present invention, however, as preferably embodied, a web ofthermoformable material to be formed into cover 11 is first heated to asufficient forming temperature. The web is then formed into the hollowcylindrical protrusion 32 with a closed end. The closed end portion ofthe cylinder 32 is then further deformed in its central section tocreate the tip 34. At the moment tip 34 is completely formed, theintersection of the base of tip 34 and cylinder 32 is compressed,reducing its thickness, to thereby create a fault line extending aboutthe periphery of the base of tip 34.

Also in accordance with the present invention, as here preferablyembodied, aperture-forming protrusion 30 is formed by means of aself-centering and self-aligning male and female punch and dieapparatus, indicated generally at 40, as shown in FIGS. 4-7.

Apparatus 40 includes feed rollers 42 or other means to advance the webor film "F" of thermoformable material into a heating station 44 where aheater block 46 advances against the film to press the sheet against astationary heater block 48, which is temperature controlled by athermocouple 50 and supplied with necessary power at connection 51. Anair cylinder 52 provides the driving force to move the heater block 46by means of shaft 54. The heater block 46 includes two heaters energizedby an appropriate power source 58.

A two-stage punch member 60 includes a first male punch 62 formed as agenerally cylindrical hollow punch having a substantially flat endsurface 64 at its operative end. When the first punch member isadvanced, the end surface 64 engages and deforms the heated sheet ofthermoformable, preferably plastic, material F, compressing the plasticagainst a similarly shaped, oppositely mounted, generally cylindricalhollow anvil member 66 movable in a bore 68 of a support 70. The anvil66 has an end face 71. The first punch 62 has a clearance fit with thebore 68 so it can be moved therein to confront the end face of the anvil66. Anvil 66 has an aperture bore 67 formed as part of its hollowportion.

Anvil 66 is part of a spring-loaded rocker member 72, preferablysupported by a ball-shaped member 74, or other similarly shaped curvedrocker device, in a larger base opening 75 so as to be both resilientand self-centering and self-aligning with punch member 60. Althoughrocker 74 is preferably curved or ball-shaped, a relatively flat surfacein spring-mounted engagement with the base of adjustable mechanism 89also serves to self-center the aperture opening 67 of anvil member 66with respect to frusto-conical surface 84 and bevelled surface 83 ofsecond punch 80, more fully described hereinafter. The peripheral edgeor rim of aperture 67 in anvil 66 is smaller than the bore of punch 62to create an internal shoulder 76 when the opposing substantially flatend surfaces 64, 71 of the hollow cylindrical punch member 62 and theanvil member 66 are brought together. The anvil and first punch arepreferably made of hardened steel.

In use, at the end of the first stage of the formation of theaperture-forming protrusion 30, shown in FIG. 5, the plastic web F isformed into a projecting, closed end, hollow generally cylindricaldrum-like shape, with the plastic web stretched across the end of thefirst generally cylindrical hollow punch, and clamped between theopposed facing end surfaces 64, 71 of the punch and anvil members.

A second punch member 80 is mounted for travel within a hollow bore 81and beyond the end face 64 of the first punch member 62. The secondpunch member 80 includes a shaft 82 whose operative end surface includesa shallow bevel 83, advantageously on the order of 45°, terminating intoa conically-shaped portion 84 with a flat end face 85 forming afrusto-conically shaped tip, indicated generally at 86. The second punchmember and its bevel 83 advances into controlled engagement with theinternal peripheral edge of the shoulder 76 formed at the opposed endsurfaces 64, 71 of the first punch 62 and anvil 66.

In one aspect of the present invention, as preferably embodied, thesecond punch member 80 can be constructed in multiple parts. Forexample, each of the frusto-conical and beveled portions 84, 83 may beformed separately and removably attached to the leading end surface ofthe shaft 82, such as by threaded connections. Alternatively, shaft 82and tip portions 83, 84 may be formed as an integral unit. The secondpunch member is driven by air cylinder 87.

It will be understood from the foregoing that the full length of thefrusto-conical end 86 of punch 80 continues to travel past the formedinternal shoulder 76 and into the anvil aperture 67 until such time asbevel surface 83 is brought into accurately controlled cooperatingengagement with the internal peripheral edge of the internal shoulder 76formed by the opposed end surfaces 64, 71 of the first punch 62 and theanvil 66. Advancement of punch surface 83 against shoulder 76 isaccurately controlled by micrometer punch adjustment mechanism 88 andanvil adjustable stop mechanism 89.

The still-heated closed end of the initially formed hollow cylinder 32,i.e., the first drum-like protrusion of the aperture-forming structure30 is, in a second stage, further formed into a substantiallycylindrical or frusto-conically shaped tip 34, i.e., the secondprotrusion of the aperture-forming structure 30, by the advancing secondpunch member until the shallow bevelled surface 83 of punch 80 engagesthe plastic sheet. At that time, the second punch surface 83controllably compresses, cools and sets the plastic web F against theinternal peripherally extending edge formed at shoulder 76 of the anvilto reduce the thickness, and thereby weaken, the wall of the plastic atthe locus of the peripheral edge so as to form a narrow, peripherallyextending indentation 100, known as a rupture or fault line, at the baseof tip protrusion 34. It will be seen that fault line 100 permits thetip protrusion 34 to be readily broken away by means of only lightlateral pressure to thereby form a nozzle-like outlet opening at neckprotrusion 32.

It should be noted that changes in the dimensions of the beveled end 86and the anvil 66 are within the scope of the present invention. Forexample, it is often desirable to produce a fine stream of the contentsof a container, such as motor oil. Consequently, the opening formed bythe base of the tip protrusion 34 must be relatively small, such asshown in FIG. 8a. To form such a aperture-forming protrusion structure30, the end 86 is elongated, and the beveled surface 83 is positionedcloser to the distal end 85. Furthermore, the anvil 66 is provided witha relatively narrow opening. Consequently, as shown in FIG. 7a, thefault line 100 and the breakaway tip 34a are smaller. Alternatively, theentire punch 82 and, therefore, protrusion structure 30 is madenarrower.

In other applications, where the contents of a container are largeparticles, such as cat food, the opening must be relatively large, suchas shown in FIG. 7b. To achieve a larger opening, the entire punch 82and, therefore, protrusion structure 30 are made wider. Alternatively,the fault line 100 and the break away tip 34 are made larger.

In an alternate embodiment illustrated in FIGS. 12 and 13, a singlepunch 90 with a truncated end 92 can be used. The single punch 90includes a bevelled surface 94 which engages the film or web F ofthermoplastic material to form the generally frusto-conical hollow tipprotrusion 34. As here embodied, thermoplastic web F is first clampedbetween shoulder plate 96 and face 97 of an outer punch member similarto punch 62. Thereafter, punch 90 advances, whereupon end 94 forms web Finto frusto-conical tip 34, as shown as FIG. 13. As alternativelyembodied, however, as best seen in FIG. 12, upon completion of theformation of tip 34, the peripheral edge 76a of anvil member 70 engagesand compresses the outer surface of the frusto-conical wall of tip 34 tocreate a peripherally extending fault line 100a along the projectingsurface of tip 34 between its base and apex.

In yet another alternative embodiment illustrated in FIGS. 12a and 13a,a single punch 91 with a beveled, truncated end 93 can be used to formthe generally frusto-conical hollow tip protrusion 31. The single punch91 engages the film or web F of thermoplastic material with the beveledsurface 93. As with the embodiment shown in FIGS. 13 and 14, thethermoplastic web F is first clamped between stop plate 95 and clampmeans 98 of an outer punch member. Thereafter, punch 91 advances,whereupon end 93 forms web F into the frusto-conical tip 31. As bestshown in FIG. 13a, contact of the peripheral edge 77 of angle member 71compresses the outer surface of the frusto-conical tip 31 to create aperipherally extending fault line 100b. In contrast to the embodimentshown in FIGS. 12 and 13, the stop plate 95 is situated adjacent theshaft of the punch 91, below the beveled, truncated end 93.Consequently, the thermoplastic web F is formed around the beveled end93 as well as the right cylindrical shaft 91a. As can best be seen inFIG. 13a, the resulting frusto-conical tip 31 has a breakaway tip 35, apermanent projection 33, and a bright cylindrical section 33a. The rightcylindrical section 33a is provided so a cap may be securely engagedwith the tip 31.

In an alternative embodiment illustrated in FIG. 12b, a single punch 91Bhas a spherical tip 93A. The spherical tip 93A engages the thermoplasticweb F to form a hollow mound protrusion. As embodied, the thermoplasticweb F is first clamp beneath a stop plate 95A. Thereafter, punch 91Badvances, whereupon the spherical end 93A forms web F into a hollowmound. Furthermore, the punch 91B is advanced forwards anvil 71A untilthe outer surface of the web F engages the peripheral edge 77A of anvilmember 71A, thereby creating a fault line that extends around the tip ofthe mound structures. It has been found that the spherical tip 93Aallows for self alignment of the punch 91B as the web F engages theperipheral edge 77A of the anvil 71A.

Referring now more particularly to FIGS. 15-18 of the accompanyingdrawings, there is illustrated an alternate embodiment of the dispenserpackage of the present invention, indicated generally by referencemanual 200. As here embodied, cover 211 includes a lateral extension211a which extends beyond one end of the container pouch 222 and boththe aperture-forming structure 230 and reclosure cap member 240 areformed in cover extension 211a. A shallow channel member 250communicates aperture-forming structure 230 with the contents of pouch222. Further alternatively, as shown in FIG. 17, lateral extension 211aof cover 211 is formed on an angle with respect to cover 11 so as toslope toward the pouch side of cover 11.

It has been found that the embodiments of FIG. 14-17 are advantageous inthat they facilitate dispensing the contents of the package onto asurface, such as butter or cream cheese onto a slice of bread ortoothpaste onto a toothbrush.

Referring now more particularly to FIGS. 18-20, there are shown severalother alternative embodiments of the cap member of the presentinvention. Thus, as shown at FIG. 18, the top of resealing cap 110 mayinclude bristles or nubs to function as a brush member; as shown in FIG.19, the top of cap 110 may have a flattened surface 270 capable offunctioning as a spreading tool; as shown in FIGS. 20a-d, cap 110 may beopen-ended and have a shaped edge configuration, such as shown at 280,281, 282, 283, respectively, so that the contents of the package may beexpelled in a shaped stream.

With reference to FIGS. 21a-b and 22a-c, an alternate embodiment of thepresent invention will now be shown and described. In accordance withthis alternate embodiment, an independent thermoformed unit is used tocreate an outlet aperture in a container. The independent thermoformedunit may take the form of a reclosable outlet forming structure 300. Thereclosable outlet forming structure 300 may generally comprise a cap310, a tether 320, a base 330, and a breakaway outlet tip 340. Cap 310may be connected to base 330 via tether 320. Score 325 facilitatesseparation of the cap 310 from structure 300. The reclosable outletforming structure 300 may have a pre-applied adhesive or sealant in thearea surrounding the base 330 to facilitate application of the structure300 to a container, such as milk container 302. As such, the structure300 may be sealably or adhesively attached to any surface of a containerrequiring the subject outlet. In particular, the structure 300 may besealed or adhered to the container in an area surrounding a hole in thecontainer, but not in the area of the cap 310 or tether 320 which mustbe free of the container's surface. It is to be understood thatreclosable outlet forming structure 300 may be attached to containers,such as milk carton 302, prior to filling. As such, the structure 302may be applied to a container when it is still a flat blank.

With reference to FIGS. 22a-d, use of the reclosable outlet formingstructure 300 will now be shown and described. With reference to FIG.22a, prior to shipping of the container 302, the cap 310 may be placedover the outlet forming structure base 330 prior to removal of thebreakaway tip 340 so as to assure that the breakaway tip 340 does notaccidentally break and the contents of container 302 do not escape whilethe container 302 is in transit. With reference to FIG. 23b, the cap 310is removed from base 330 to provide access to breakaway tip 340. Thecontainer at this point is ready for opening. With reference to FIG.23c, the breakaway tip 340 is then removed to create an opening 350.Opening 350 leads to a hole (not shown) in container 302 to allowpouring the contents of container 302 therethrough. With reference toFIG. 23a, the reclosable outlet forming structure 300 may be resealed bysimply placing the cap 310 over base 330.

In one embodiment of the present invention, base 330 and tip 340 arecylindrical or substantially cylindrical, although it is to beunderstood that other shapes may be used. In this embodiment, theopening 350 is made of PET-PVC-BAREX. It is to be understood, however,that other materials in accordance with the present invention may beused.

As can be seen in FIG. 22d, the cylindrical outlet 330 and opening 350act a nozzle direct the flow of the contents of the container 302 into acontrol stream.

With reference to FIGS. 23-26, a low profile breakaway tip and cap inaccordance with another embodiment of the present invention is shown. Ingeneral, lowering the height of a breakaway tip 360 will lower thepossibility that the tip 360 may be accidentally opened during transitor by handling. Lowering the height of the breakaway tip makes it moredifficult, however, to grasp and remove the breakaway tip. Thisdifficulty is alleviated by creating undercuts or indents 370 in thesidewall of the breakaway tip 360. These undercuts or indents 370 allowsa user's finger to hook and break away the tip 360 in a single motion.FIG. 25 is a perspective view of the low profile breakaway tip with theremoved breakaway tip shown in phantom. With continuing reference toFIGS. 23-25, the undercuts or indents 370 are preferably arranged inopposed positions to facilitate ease of use and manufacture. It is to beunderstood that the number and location of the undercuts/indents 370 maybe varied. Once the breakaway tip 360 is removed from base 380, a cap394 may be used to reclose the opening (not shown) exposed by theremoval of tip 360 in base 390. Base indents 392 in base 380 are shapedand dimensioned to receive opposed inward protrusions 396 of cap 394.These protrusions 394 snap into indents 392, thereby securing cap 390 tobase 380. A tether (not shown) may also be used to attach cap 390 tobase 380.

As shown in FIGS. 23a and 24a, the base 390a may have generallytriangular cross-sectional area. Such a cross-sectional area, may aid inthe dispensing of various materials. Furthermore, the relatively largebottom of the base 390a helps avoid accidental toppling of a container.

It is also to be understood that this embodiment of the presentinvention may be used in a wide variety of applications, includingdispensers for creamers, unit dose medications, salad dressings, beautyaids, dental products, condiments, candy confections, syrups, granularproducts, etc. It is also to be understood that this embodiment of thepresent invention may be manufactured by utilizing a male punch memberin conjunction with a self-centering and receding female anvil system,as previously shown and described.

Although the use of a tether limits the rotation of a cap pressed onto abase formation, a twist-lock or twist-threading arrangement may also beused to secure the cap to the base. With reference to FIG. 28, such anembodiment of the present invention which utilizes a twist-lock ortwist-threading arrangement 400 to secure the cap 410 to the baseformation 420 is shown. In this arrangement, cap 410 has an innerprotrusion 415 which engages cam surface 430 of base 420. Upon rotationof cap 410 with respect to base 420, inner protrusion 415 engages camsurface 430 to create a twist-lock or twist-thread arrangement. It is tobe understood that a tether (not shown) may also be used in such anarrangement. Base 420 may also have a breakaway tip 425 attachedthereto.

As an alternative to the breakaway tip and tethered cap arrangement, thepresent invention also includes a tethered plug/punch and scored surfacearrangement as shown in FIGS. 28a-c, 29a-d and 30a-d. FIGS. 28a and 28bare perspective views of such an embodiment of the present invention inwhich a tethered plug is used to open and close a pre-scored surface. Inthis arrangement 450, a plug 460 is used to open a pre-scored surface470 of outlet 480. In this embodiment, the score is in the form of aninterrupted circle, although it is to be understood that other types ofscored surfaces, such as those shown in FIGS. 29a-d, may also be used.FIGS. 28b and 28c depict a flap 485 which is created when plug 460 isused to penetrate the scored surface 470. A tether 490 may also becreated through the use of a score 495 in arrangement 450. Plug 460,which may be connected to arrangement 450 via this tether 490, may alsobe used as a cork to close the outlet hole. As such, plug 460 may beused both as a plug and as an opening tool to create and/or plug anaperture in the pre-scored surface. In this embodiment, plug 460 has aconical shape, although it is to be understood that other shapes may beused. Similarly, as shown in FIGS. 28a and 29a-d, the score may have apartially circular shape, a V-shape, an X-shape, a star shape, or boxshape, although it is to be understood that other patterns may also beutilized. Depending on the shape of the scored surface, the flap createdby the penetration of plug 460 will differ. For example, the penetrationof scored V-shaped surface 490 will create a flap 491; the penetrationof scored X-shaped surface 492 will create a flap 493; the penetrationof scored star-shaped surface 494 will create a flap 495; and thepenetration of a scored surface 496 will create a rectangular-shapedflap 497.

An alternative embodiment of the present invention will now be discussedwith reference to FIGS. 31-36. In accordance with this alternativeembodiment, a container 500 is provided with a reclosable outlet formingstructure 510. More specifically, the outlet former structure 510comprises a curvilinear dome or mound 530 and a dual purpose punch/plug520. As will be apparent to one of skill in the art, the container 500includes a hole, not shown, over which the mound 530 is secured. Becausethe punch/plug 520 must be lifted and inverted for insertion into thescored area 532, it must not be sealed to the container 500. On theother hand, the mound 530 portion of the outlet forming structure 510must be securely adhered over the hole in the container 500.

As can best be seen in FIG. 34, the outlet forming structure 510comprises a layer of foil 534 laminated to the plastic forming theoutlet forming structure 510. The portion of the foil 534 underneath themound 530 should be unsupported other than the adhesive used to secureit to the mound 530. It should also be noted that the foil 534 issecured to the container 500, about the hole in the container 500, sothat the contents do not leak out beneath the outlet forming structure510. The foil laminated adhesive should be one that gives adequateadhesion but sets up with minimal tensile strength of its own. Inalternative embodiments, the adhesive may approach being brittle.

The mound 530 further includes a fault line pattern or scored pattern532. The fault lines 532 may take on any number of patterns, such asthose shown in FIGS. 29a-d. As shown in FIGS. 35 and 36, the foil 534 islaminated to the entire surface of the mound 530 and preferably, is notscored. In an alternative embodiment, the adhesive may be omitted fromthe fault line pattern 532.

The punch/plug 520 is secured to the outlet forming structure 510 via atether 524. The tether 524 is created by a cut 522 through thefoil/plastic laminate. As can best be seen in FIG. 32, the cut 522preferably takes a curvilinear path, following the periphery of theoutlet forming structure 510. Such a cut 522 provides an elongatedtether 524.

In operation, the punch/plug 520 is firmly pushed into the fault linepattern 532 to rupture the scored mound 530. This operation is bestshown in FIG. 35. Having forced the punch/plug 520 through the scoredarea 532 of the mound 530, an opening for dispensing the contents of thecontainer 500 is formed. The punch/plug 520 is removed from the mound530 so that contents of the container 500 may be dispensed. Because thescored area 532 has been deformed to the shape of the punch/plug 520,the punch/plug 520 may be reinserted into the scored area 532, therebyresealing the container 500.

In an alternative embodiment, however, the foil layer 534 may span thehollow base of the mound 530 by being laminated only to the periphery ofthe mound. Of course, in such an embodiment, the punch/plug 520 must belong enough to extend past the plane of the foil 534 so that the foil534 may be punctured. By wobbling the punch/plug 520 while inserted intothe mound 530, the opening in the foil is enlarged.

It should be noted that the mound 530 strengthens the outlet formingstructure 510. Furthermore, the shape of the mound 530 provides a nozzlefunction, directing the contents of the container 500 in an even stream.Depending upon the contents of the container 500, the dimensions andshape of the mound 530 may be altered to provide the desired flow.

The outlet forming structure 510 of FIGS. 31-36 are preferablymanufactured with a punch similar to that described with reference toFIG. 12b. Of course, the tip of the punch need not be spherical, butrather may be elliptical, parabolic, or any curvilinear shape.Furthermore, it is preferred that the foil and plastic be laminated intoa single web prior to the formation of the mound be the punch. Thus, thedimensions of the mound, as defined by the shape of the punch tip, willbe limited only be the physical properties of the materials used.

In an alternative embodiment, which will now be described with referenceto FIGS. 37-38, a reclosable outlet forming structure 610 according tothe present invention is utilized with a flexible plasti-foil pouch 600.In general, the foil pouch 600 is formed by folding a generallyrectangular shaped piece of the foil plastic combination in half andsealing the three open edges thereof. A reclosable outlet formingstructure 610 is mounted on the seamless end 605 of the pouch 600. Theoutlet forming structure 610, which is sealed to the seamless end of thepouch 600 by applying an adhesive around a periphery of the base 612,covers a hole, not shown, in the pouch 600.

The outlet forming structure 610 may be of any type previously disclosedabove, such as those described with reference to FIGS. 1-3, 8-9, 13, and13a. In a preferred embodiment, as shown in FIGS. 37 and 38, the outletforming structure 610 includes an aperture forming protrusion 630. Morespecifically, the aperture forming protrusion 630 includes a hollowcylindrical base 632 and a break-away tip 634. A fault line 636 extendsaround the periphery of the protrusion structure 630, permitting thebreakaway tips 634 to be broken away from the base 632 in the tip 634.More specifically, the fault line 636 is a narrowed, stressconcentrating area.

The outlet forming structure 610 also includes a cap 620. The cap 620 isa hollow tapered member, which has an inside base diameter slightlylarger than the outside diameter of the base 632 of the protrusionstructure 630. The cap 620 is secured to the outlet forming structure610 via a tether 624. The tether 624 is formed by a cut 622 through thelower surface 612 of the outlet forming structure 610. As can best beseen in FIG. 39, the curvilinear cut 622 separates the cap 620 from theprotrusion structure 630 and follows the periphery of the base 612. Byhaving such a pattern, the cut 622 is relatively long and, consequently,produces a relatively long tether 624. Due to the long tether 624 andthe fact that the portion of the base 612 that supports the cap 620 isnot fastened to the pouch 600, the cap 620 may be raised and securelyplaced over the outlet forming structure 630.

In operation a user applies sidewise finger pressure to the protrusiontip 634, thereby causing it to break away from the protrusion base 632along a fault line 636. Because the protrusion structure 630 issubstantially hollow, an aperture, not shown, is created. Furthermore,because the protrusion member 630 has been affixed to the pouch 600 overa hole in the pouch, not shown, the contents of the pouch 600 may bedispensed via the now opened protrusion neck 632. The cap 620 is placedover the base 632 during shipping, so that accidental rupturing of thefault line 636 is prevented. Furthermore, cap 620 is placed over thebase 632 to reclose the package 600 when only a portion of the contentsof the package 600 has been dispensed.

In an alternative embodiment, shown in FIG. 39, the same outlet formingstructure 610 is secured to the side of pouch 640. In this embodiment,the pouch 640 is formed from two generally rectangular sheets of foilplastic laminate which are sealed together around all four sides of eachsheet. As with the previous embodiment, the protrusion structure 630 isaffixed to the pouch 640 over a hole, not shown, so the protrusion neck632 is in fluid communication with the contents of the pouch 640.

An alternative embodiment of the present invention employing an outletforming structure 610a disposed on a foil pouch 640a will now bedescribed with reference to FIGS. 37a, 38a, and 39a. Briefly described,the outlet forming structure 610a is substantial the same as the outletforming structure described with reference to FIGS. 37-39. Specifically,the outlet forming structure 610a includes both a cap 620a and aprotrusion member 630a. As best seen in FIG. 39a, the foil pouch 640aincludes a lap seam on the side opposite the outlet forming structure610a.

An alternative embodiment of the present invention will now be describedwith reference to FIG. 40. A tethered punch/plug and base member with astar shaped fault pattern manufactured as a unit 700 is shown. A tether730 is connected to the base 710 at a proximal end thereof, a ringstructure 740 connected to a distal end thereof, and a taperedpunch/plug 760. The punch/plug 760 is manufactured separately from theother components.

As shown, the ring structure 740 defines an opening 750. The opening 750is larger than the tip 762 of the punch/plug 760 yet smaller than thebase 764 of the punch/plug 760. Furthermore, the punch/plug 760 includesa circumferential indentation 766. The indentation 766 is formed on thepunch/plug 760 just below a point where the outside diameter of thepunch/plug 760 becomes larger than the inside diameter of the opening750.

Therefore, once the components have been separately manufactured, thepunch/plug 760 is snapped into the opening 750. When snapped into theopening 750, the tapered punch/plug 760 causes the slightly elastic ringstructure 740 to expand until the ring structure 740 reaches theindentation 766. Upon reaching the indentation 766, the ring structure740 snaps into the indentation 766. Consequently, the punch/plug 760becomes connected to the ring structure 740 and the other components.

In use, as shown in FIG. 40a, the punch/plug 760 is used to puncture thescored section 722 of the protrusion structure 720. Such operation isdescribed in greater detail with reference to FIGS. 28-30d.

Turning now to FIG. 41, one embodiment for manufacturing a reclosableoutlet forming structure according to the present invention is shown.Specifically, a pair of reclosable outlet forming structures 870 and 880are formed from the same piece of thermoplastic web F. Each reclosableoutlet forming structure 870, 880 comprises a protrusion structure 872,882 as well as cap 874, 884, respectively. As in the previouslydisclosed embodiments, each cap 874, 884 is connected to thecorresponding protruding structure 870, 880 via a tether 876, 886.

It is to be understood that the mating, horseshoe arrangement of theoutlet forming structures 870, 880 provides several benefits, such asreclining wasted portions of the web F, and that the manufacturingagreement may be repeated along the length of the web F.

Turning now to FIGS. 42-44, an alternative embodiment of the presentinvention is shown. Initially, it should be noted that the container1000 shown is made of similar materials as described above withreference to FIGS. 1-3.

The container 1000 comprises a first deformable pouch 1010 and a seconddeformable 1020. The two pouches 1010, 1020 are joined by a shallowconduit 1030. The deformable pouches 1010, 1020, as well as the joiningconduit 1030, are sealed by a generally flat sheet 1040 ofthermoformable plastic material. A hollow protrusion 1050 is integrallyformed with the flat sheet of thermoformable plastic 1040. The hollowprotrusion 1050 extends from the flat sheet 1040. The protrusion 1050 isdirectly above and in fluid communication with the conduit 1030. Thecontainer 1000 further includes a punch/cap 1060.

As can best be seen in FIG. 43, the hollow protrusion 1050 has scores orfault lines 1055 on the top face thereof. Despite these fault lines1055, which weaken the protrusion 1050, the container 1000 remainssealed. Further shown in FIG. 46, the punch/cap 1060 is partiallyseparated from the remainder of the container 1000 by cut 1062. The cut1062 which parallels one peripheral edge of the container 1000 creates atether 1064.

In order to open the container 1000, the punch/cap 1060 is positionedover the protrusion 1050. The punch/cap 1060, and more specifically thepointed end 1066 of the punch/cap 1060 is forced through the score orfault lines 1055, thereby opening the hollow protrusion 1050. Whenpunch/cap 1060 is removed from the hollow protrusion 1050, an opening,not shown, exists. The opening is formed by the permanent deformation ofthe portion of the protrusion member 1050 between the fault lines 1055.By inverting the container 1000 and gently squeezing either or both ofthe pouches 1010, 1020 the material contained within the pouches isdispensed via the opening in the protrusion 1050.

It should be noted that in the preferred embodiment the protrusion 1050is placed directly above the conduit 1030. As a result, the contents ofthe pouches 1010, 1020 can be dispensed in a controlled manner.Specifically, the shallow conduit 1030 provides resistance to theflowing contents so that the contents do not spout from the openedprotrusion 1050 uncontrollably, particularly when the protrusion 1050 isinitially punctured.

As shown in FIG. 44, should less than all of the material containedwithin the pouch 1010, 1020 be dispensed, the container 1000 may bereclosed. Specifically, the punch/cap 1060 is inverted by twisting thetether 1064. Because the punch/cap 1060 is hollow, having an insidediameter substantially the same as or slightly larger than the outsidediameter of the protrusion 1050, the punch/cap 1060 can be securelyplaced on the protrusion 1050.

With regard to the embodiment of FIGS. 42-44, it will be apparent to oneskilled in the art that the invention is not limited by the type ofoutlet forming structure utilized. Specifically, any combination ofbreak away tip, scored protrusion member, punch, plug, and cap may beemployed. Furthermore, it should be understood that the particular shapeof the pouches may vary according to the properties of the contents heldtherein.

An alternative embodiment of the present invention will now be describedwith reference to FIGS. 45-47. As shown in FIG. 45, an outlet formingstructure 1070 comprises a cap member 1072 and an aperture formingprotrusion 1074. As with the embodiments discussed above, the cap member1072 is connected to the aperture forming structure 1074 by a tether1076. As can be seen, both the cap member 1072 and the aperture formingstructure 1074 are formed in a curvilinear base 1078.

Because the outlet forming structure 1070 is formed in a curvilinearbase 1078, it may be positioned on a container 1080 having a similarcurvilinear surface. As shown in FIGS. 46a-c, one such container 1080 isgenerally spherical and formed in two halves 1082, 1084. The two halves1082, 1084 are joined at one point along their circumferences, and aretherefore hingeably connected. One half 1084 of the container 1080includes an aperture 1086 formed therein.

In operation, as shown in FIG. 47, the outlet forming structure 1070 isaffixed to the container 1080 such that the aperture forming structure1074 is in alignment with the aperture 1086 in the container 1080. Asfurther depicted in FIG. 47, the cap member 1072, shown in a sectionalview, may be positioned over the aperture forming structure 1074,thereby protecting it and sealing the container 180. It is to beunderstood that the shape of the container 1080 is merely representativeof those that may be employed with the present invention, as the outletforming structure may be formed on a curvilinear base having virtuallyany shape.

Another alternative embodiment of the present invention will now bedescribed with reference to FIGS. 48-51. The container 1090 generallycomprises a rectangular sheet 1091 of thermoformable material. At thecenter of the rectangular sheet 1091 is an aperture forming structure1092, having a base and break away tip as described above with referenceto the prior embodiments. On either side of the aperture formingstructure 1092 are pouches 1098 formed on the underside of the sheet1091 for holding any flowable substance. The pouches 1098 are in fluidcommunication with the aperture forming structure 1092.

Also formed in the rectangular sheet 1091 of thermoformable material isa cap member 1094. The cap member 1094 is preferably formed in onecorner of the rectangular sheet 1091 and attached to the container 1090via a tether 1096. The tether 1096 is formed by a cut 1097 extendingalong the perimeter of the container 1090.

The container 1090 may be folded generally in half along bending grooves2006 disposed on either side of the aperture forming structure 1092.Specifically, the ends of the container 1090 are brought together asdepicted by arrows "A" in FIG. 49. Once the ends are brought together, afemale package tie 2000 and a male package tie 2002, both of which areintegrally formed in the sheet of thermoformable material 1091, arebrought into engagement.

Engagement of the female package tie 2000 and the male package tie 2002hold the container 1090 in the configuration as shown in FIGS. 50 and51. In operation, lateral finger pressure on the tip of the apertureforming structure 1092 causes a fault line to rupture, thereby formingan aperture in the aperture forming structure 1092. Thus, the contentsof the container 1090 may be dispensed from the aperture. As shown inFIG. 51, the cap member 1094 may be placed over the aperture formingstructure 1092, thereby preventing accidental rupturing of the faultline or accidental dispensing of the contents after the tip of theaperture forming structure 1092 has been removed.

Another alternative embodiment of the present invention will now bedescribed with reference to FIGS. 52-54. As shown in FIG. 52, anaperture forming structure 2016 according to the present invention maybe positioned on a treated paper board tube 2012, thereby forming asealed container 2010. The aperture forming structure 2016 comprises agenerally hollow frusto-conical portion 2018, a hollow cylindricalportion 2019, and a breakaway tip 2020. Integrally formed with theaperture forming structure 2016 is a cap member 2022 and an associatedtether 2024. As can best be seen in FIG. 54, the tether 2024 is formedby a curvilinear cut which allows the cap member 2022 to be partiallyseparated from the aperture forming structure 2016 so that the capmember 2022 may be positioned over the cylindrical portion 2019 and thebreakaway tip 2020. Because the cap member 2022 has an inside diameterslightly larger than the outside diameter of the cylindrical portion2019, the cap member 2022 fits snugly thereon, thereby sealing thecontainer 2010.

As with the previously described embodiments, in operation, lateralpressure on the breakaway tip 2020 causes it to separate from the restof the aperture forming structure 2016, thereby forming an aperture intothe generally hollow aperture forming structure 2016. Thus, the contentsof the container 2010 may be dispensed therefrom.

It will remain understood by those skilled in the art that the presentinvention in its broader aspects is not limited to the particularembodiments shown and described herein, and that variations may be madewithout departing from the principles of the invention and withoutsacrificing its chief advantages.

I claim:
 1. An aperture forming means for dispenser containerscomprising a break away tip member made of thermo-formed plastic filmcomprising a hollow protrusion from a surface whose interesection withsaid surface comprises a locus of a fault line, wherein said surfacehaving said hollow protrusion sits on an additional hollow protrusionbase member formed and protruding from said thermo-formed plastic filmto create a nozzle, said aperture forming means further comprising atleast one additional hollow protrusion adjacent said hollow protrusionbase member, wherein said at least one additional hollow protrusion hasan open end and a closed end, said open end being a cap member and saidclosed end being a punch or a plug.
 2. An aperture forming means fordispenser containers comprising a break away tip member made ofthermo-formed plastic film comprising a hollow protrusion from a surfacewhose interesection with said surface comprises a locus of a fault line,wherein said surface having said hollow protrusion sits on an additionalhollow protrusion base member formed and protruding from saidthermo-formed plastic film to create a nozzle, said aperture formingmeans being integrated with a squeezable dispensing container having aseal at each end and a single longitudinal seal.
 3. The aperture formingmeans of claim 2 where said squeezable dispensing container is made of apaperboard product treated to create suitable barrier characteristicsfor a product contained in the paperboard product.
 4. The apertureforming means of claim 2 made of a thermoplastic which is Barex coatedwith Polyvinyl dichloride.
 5. The aperture forming means of claim 2where said squeezable dispensing tubelike container is made of athermoplastic wherein the aperture forming means is thermoformed into ahollow portion of a tube.
 6. The aperture forming means of claim 5wherein said at least one additional hollow protrusion is formed into anend fin seal, said end fin seal being so cut as required so as to createa tether for said at least one additional hollow protrusion.